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I used 40x80 extrusion, most recommend 45x90 but this size was more availible for me.
If doing it again I would order 45x90 :)

Connected the profiles with t nuts in one extrusion. Then drilled...

Very simple. The linear bearing carriages are bolted to a 12mm aluminium plate with cap screws in counter-bored holes so that bolt heads are below the surface. In effect, I then have a linear bearing...

The title? Medium-size – bigger than a bench-top machine but not as big as a “full-sheet” 8x4. Steel-framed – basic structure is steel box section throughout, including the gantry, no aluminium...